Safety technology

KeSafe – Safe Machines, Systems & Robot

Modular safety solutions for machines, plants, and robot systems

KeSafe combines a powerful safety CPU with certified function blocks to implement modern safety requirements quickly, flexibly, and in compliance with standards. Our KeSafe safety solution has a modular design and consists of three function levels:

KeSafe PLC for safe logic functions,
KeSafe Motion for safe axis applications,
KeSafe Robotics for safe robot functions.

KeStudio SafeEdit is the integrated safety programming tool within the KEBA Engineering Suite KeStudio.
It is freely programmable and enables the convenient creation, diagnosis, and validation of safety-related applications for machines and robot systems.

Both simple safety functions and complex robot-specific safety applications can be implemented efficiently.

Industry solutions

KeSafe safety technology is suitable for robotic systems, machines with hazardous movements, packaging, assembly, and production systems, special-purpose machine construction, and series machines that require a flexible safety configuration.

KeSafe offers innovative safety technology that helps mechanical engineering companies make their systems more efficient, reliable, and future-proof. With modular safety controllers, seamless integration into existing automation environments, and maximum performance, KeSafe enables precise and rapid response in safety-critical situations.

Benefits of KeSafe for mechanical engineering at a glance:

Maximum safety through certified safety functions
Modular and scalable for flexible machine concepts
High performance for fast response times
Easy integration into existing automation systems
Less downtime thanks to efficient diagnosis and implementation

The KeSafe products integrated into our Kemro X CNC solution provide safety technology for machine tools. The safety-related functionality of our solution consists of interaction between the safety products of the central control unit and the drive system. The integrated safety solution ensures the safe operation of machine tools in accordance with the EN ISO 16090-1 standard for machine tool safety.

Benefits of KeSafe for machine tools at a glance:

Programmable central safety control that interacts with all safety elements
Interoperability between logic control (PLC) and safety control (SCP)
Easy adaptation to machine options and versions
Safety based on abstracted, reusable, and certified basic functions for logic, motion, and technology
Available for a wide range of applications

Modular system concepts in intralogistics often result in complex, customer-specific safety applications with high engineering, maintenance, and recertification costs. Different software variants further increase this complexity. The KeSafe C5 Safety Platform from KEBA reduces this effort with a modular, standardized safety application. Adjustments are no longer made via programming, but via predefined options. Machine and system configurations can be automatically transferred from ERP systems and mapped directly in the safety application.

Benefits of KeSafe for intralogistics at a glance:

Modular safety applications based on a uniform software structure
Variant creation through configuration instead of customer-specific programming
Reduction of parallel software streams
Automated transfer of machine configurations from ERP systems
Simplification of maintenance, changes, and recertifications

OEMs and series machine builders need to combine process-critical applications such as painting, welding, gluing/sealing, pick-and-place, and packaging safely, efficiently, and in compliance with standards using modern robotics systems.

KeSafe D3 Safety offers pre-certified robotics safety functions that are seamlessly integrated into the open Linux-based Kemro X control system. This allows specific process know-how to be directly translated into a safe robotics solution that meets the current requirements of ISO 10218-1:2025 – all on a single controller.

Benefits of KeSafe for integrated robotics at a glance:

Pre-certified robotics monitoring modules for all serial kinematics
From high-resolution encoders (EnDAT 2.2 or HDSL) to robust heavy-duty encoders (resolvers): the right encoder for every application
Safety solution with rated currents from 1.5 to 210 A
Safety based on abstracted, reusable certified basic functions for logic, motion, and robotics

Injection molding machines offer a wide range of options and modular machine concepts. In practice, this often leads to different safety characteristics and thus to high engineering, validation, and operating costs—especially in hydraulic and hybrid architectures. KeSafe C5 safety plattform from KEBA addresses precisely this complexity and enables efficient, versatile implementation of safety functions.

Benefits of KeSafe for plastics at a glance:

Safety solution specially designed for injection molding machines in the plastics industry
Hybrid safe digital outputs for efficient valve control
Reduction in the number of different safety applications through configuration with SafeEditNG
Support for modular machine and variant concepts
Compliance with high safety requirements in accordance with EU Machinery Directive 2006/42/EC and EU Machinery Regulation (EU) 2023/1230
Safety level up to PL e / SIL 3

KeSafe Hardware & Software Overview

Our open and certified safety technology solutions include hardware and software for the safe operation of machines and robots in accordance with current standards and guidelines.

KeSafe C5

Modular safety solution consisting of hardware and software for safety applications in series machine and plant construction.

Data sheet KeSafe C5

KeSafe D3-DU

Safety technology for robotics applications, used in combination with the compact KeDrive D3 control and drive system.

Data sheet KeSafe D3-DU

KeSafe D3-SDC

Drive controller with safe drive functions within the KeDrive D3 platform, monitoring movements according to current standards.

Data sheet KeSafe D3-SDC

KeStudio SafeEdit

Integrated safety programming tool with free programming within the KEBA engineering suite KeStudio.

More about KeStudio

Example of an automation solution with integrated safety

Beispiel einer Automationslösung mit integrierter Safety

Your advantages with KeSafe

Free programmability

Programming is carried out using our “KeStudio SafeEdit” software tool. This is a tool for creating and validating safety applications. The safety logic is therefore fully flexible and adaptable, rather than just being pre-configured.

Safe inputs and outputs (I/Os)

Safe onboard safety I/Os. Expandable I/Os via FSoE (Fail Safe over EtherCAT). The decentralized safety concept allows safety modules to be placed anywhere in the system.

Safety standards

KeSafe meets the highest safety standards: Category 4, PL e according to EN ISO 13849-1 and SIL 3 according to EN 62061 / EN 61508. This makes KeSafe suitable for applications with very high safety requirements (e.g., robotics, complex machines).

Certified safety function blocks

The KeSafe PLC offers an extensive library of certified safety function blocks, such as: Emergency stop, two-hand operation, enable switch, door monitoring. These blocks can be freely linked together, similar to a classic PLC – only safety-oriented.

Support for development and commissioning

Comprehensive support for the development of safety applications and the commissioning of machines and robots. This ensures that all safety functions are correctly implemented, tested, and executed according to current standards.

Smooth operation of safety and automation

The KeSafe safety solution is designed to work seamlessly with machine and robot control systems. This enables invisible but highly effective safety operation without disrupting the production flow.

Häufig gestellte Fragen

Sie haben Fragen zu unserer Plattform für Automatisierung? Hier haben wir Antworten auf die häufigsten Fragen für Sie zusammengestellt.

Kemro X steht für Offenheit in Hardware und Software. Bsp. Drives, HMI-Geräte,... können durch div. Standardschnittstellen (EtherCAT, Profinet,..) auch an 3rd Party Controller betrieben werden. Die Kemro X Runtime Environment Software setzt auf ein Debian basiertes Linux. Dies ist quell-offen und ein modular aufgebautes Betriebssystem welches von Softwareentwicklern auf der ganzen Welt weiterentwickelt wird.

Applikationen können einfach durch den Anwender installiert und deinstalliert werden. Dies kann entweder „Offline“ über USB-Stick erfolgen (auf Wunsch vollautomatisch beim Anstecken) od. Online über einen Software Server (on-premise oder in der Cloud). Im Hintergrund wird auf den Standard Debian Repository Mechanismus gesetzt.

Hier unterscheiden wir zwischen „Master“ und „Slave“. Unser Fokus ist EtherCAT (als Master bzw. auch als Slave), da dieser im Serienmaschinenbau sehr stark eingesetzt wird. Die „Slaves“ (heißt je nach Feldbus unterschiedlich – bei EtherNet IP „Adapter“, bei Profinet „Device“) unterstützen wir für Anbindungen an übergeordnete Systeme bzw. bei Einzelproduktverkauf innerhalb einer Maschine.

Dies kommt stark auf die benötige Anwendung an. Kemro X ist auf den Serienmaschinenbau ausgelegt, d.h. das Produktportfolio zur Ausstattung einer typischen Maschine ist bei KEBA vorhanden. Sollte mal ein Produkt fehlen kann dieses aufgrund der Offenheit relativ leicht integriert werden (z.B. ein Spezialgerät welches über EtherCAT eingebunden wird).

Kemro X Steuerungen nutzen Linux/Debian als Betriebssystem. Bei unseren HMI-Geräten kann zwischen Windows und Linux gewählt werden. Linux ist weitverbreitet (IoT, Server, Cloud), skalierbar, zuverlässig, läuft sehr stabil (auch auf älterer Hardware) und ist selten Angriffsziel von Schad-Software im Vergleich zu anderen Betriebssystemen. Debian ist eine bekannte Linux-Distribution. Windows wird häufig für Visualisierungsgeräte verwendet. Hauptzweck ist, wenn bestehende auf Windows basierte Tools bereits vorhanden und wiederverwendet werden.

Kemro X ermöglicht echte C/C++ Programmierung (es wird nicht im Hintergrund auf eine andere Sprache z.B. IEC code transformiert). Es können externe C-Libraries verwendet werden und es ist eine Programmierung mit beliebiger IDE möglich (KEBA bietet eine IDE als out of the box Lösung an). C/C++ ist plattformunabhängig und dadurch sehr portabel. IEC61131-3 Programmierung auf Basis von CODESYS ist ebenfalls möglich. Scripting Sprachen wie LUA oder Python können im Nicht Echtzeitkontext verwendet werden.

Neben zahlreicher Kemro X Apps können auch 3rd Party Applikationen installiert werden. Die Softwarearchitektur ist weitgehend Hardware unabhängig designed. In Kombination mit KEBA-Steuerungen ergeben sich Mehrwerte im Bereich von Service, Hardware EtherCAT mit reduziertem Jitter und schneller Regelegung, Nutzung von Realtime Clock, Retain-Daten (SRAM,...)